Honda CRF250X 2006, Owner'S Manual & Competition Handbook

Page 1: ...2006 Honda CRF250X OWNER S MANUAL COMPETITION HANDBOOK ...

Page 2: ...let given to you by your Honda dealer at the line of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voi...

Page 3: ... will find important safety information in a variety of forms including Safety Labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don ...

Page 4: ... Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74 Chassis Suspension 82 Brakes 86 Wheels 90 Tires Tubes 91 Side Stand 93 Drive Chain 94 Additional Maintenance Procedures 97 Electrical Battery 99 Headlight Taillight 100 Appearance Care 101 ADJUSTMENTS FOR COMPETITION 103 Front Suspension Adjustments 104 Rear Suspension Adjustments 118 Suspension Adjustm...

Page 5: ...dations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Important Safety Precautions 2 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 ...

Page 6: ...ep your motorcycle properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance 2 Motorcycle Safety exhaust system Wear clothing that fully covers your legs Do not wear loose clothing which could catch on the con...

Page 7: ...ycle and how you load it are important to your safety If you decide to carry cargo you should be aware of the following information Loading Guidelines As discussed on page 4 we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines Keep cargo small and light Make sure it cannot easily be cau...

Page 8: ...quipment or modify your motorcycle in any way that would change its design or operation Such changes could seriously impair your motorcycle s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your ar...

Page 9: ...els on your motorcycle Some labels warn you of potential hazards that could cause serious injury Othere provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement ...

Page 10: ...6 Motorcycle Safety ...

Page 11: ...Operating Controls 7 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your motorcycle Operation Component Locations 8 ...

Page 12: ...ting Controls Operation Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip tripmeter start button choke knob fuel valve shift lever kickstarter rear brake pedal ...

Page 13: ... get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your motorcycle For information about suspension carburetor and other adjustment see page 103 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 ...

Page 14: ...ther adjustments see page 103 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a...

Page 15: ...e speed for stable and proper RPM 132 Tires for damage or improper inflation pressure 91 Spokes for looseness 90 Rim locks for looseness 90 Front and rear suspension for proper operation 82 83 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 94 Drive chain guide sliders and guide rollers for damage or wear 96 Exhaust pipe Muffler inspection removal a...

Page 16: ...12 Before Riding ...

Page 17: ...information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 ...

Page 18: ...st time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your motorcycle s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob 1 ...

Page 19: ...ngine Hot Engine Starting 1 Pull the hot start lever 3 all the way in and start the engine following step 3 under Normal Air Temperature 2 As soon as the engine starts release the hot start lever NOTICE NOTICE Basic Operating Instructions 15 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the fuel valve ON before attempting ...

Page 20: ...e engine starts release the hot start lever Using the kickstarter 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as the engine sta...

Page 21: ...ng after the engine has been warmed and the side stand raised 1 Close the throttle and pull the front brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the front brake Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will stall...

Page 22: ...enerally reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your motorcycle When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these...

Page 23: ...Parking Lower the side stand to support your motorcycle If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park Basic Operating Instructions 19 ...

Page 24: ...n your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to lubricate the drive chain page 96 to prevent rusting 20 Basic Operating Instructions ...

Page 25: ...ying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced ...

Page 26: ...22 Basic Operating Instructions ...

Page 27: ...Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 29 Before After Competition Maintenance 33 Between Motos Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids...

Page 28: ...e ridden over rough off road terrain To help you properly care for your motorcycle this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your motorcycle to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important t...

Page 29: ...rom hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or a work stand to provide support To reduce the pos...

Page 30: ...ing days as well as miles To avoid overlooking required service we urge you to develop a convenient way to record the number of days and or miles you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda p...

Page 31: ...I R I L I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I I I I R I I I I I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I R I I R I I I I I I I I I I 41 42 55 51 53 61 66 44 44 132 49 50 49 47 94 96 96 87 89 87 100 56 93 82 83 65 98 90 91 97 FREQUENCY ITEMS EMISSION REALATED ITEMS NON EMISSION REALATED ITEMS NOTE mi km Month 100 150 1 600 1 000 6 1 200 2 000 12 I L ev...

Page 32: ...VEN SPROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 66 44 44 132 76 76 46 48 94 96 96 95 95 87 89 86 56 97 62 82 83 32 84 109 98 90 91 97 I I C I I I I I I I I L I I I...

Page 33: ...le high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre rid...

Page 34: ...o over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda Wh...

Page 35: ...ntamination Refer to Fuel System in your Owner s Manual page 41 and in this supplement Fuel System page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the fuel tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 41 Loosen the Carbur...

Page 36: ...le located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced Fork Oil Performance Disassemble clean and inspect the fork and replace the oil regu...

Page 37: ... ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi 0 kPa 0 kgf cm2 in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 2 pressure release screws 1 2 After Competition Maintenance It is im...

Page 38: ...re available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your motorcycle Avoid using stiff abrasive brushes on the plastic or rubber parts If your motorcycle was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal p...

Page 39: ...filter air cleaner battery rear suspension high speed damping adjuster rear suspension low speed damping adjuster rear brake caliper main fuse rear brake fluid reservoir rear brake redal transmission oil checkbolt transmission oil filer cap front suspension compression damping adjuster rear suspension rebound damping adjuster front suspension rebound damping adjuster clutch lever hot start lever f...

Page 40: ... 3 seat 2 collars Installation 1 Install the seat while aligning the seat front prong 4 with the seat bracket 5 and seat rear prong 6 with the tab 7 of the frame 2 Install the collars and tighten the seat bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 3 1 2 4 6 7 5 36 Servicing Your Honda 4 seat front prong 5 seat bracket 6 seat rear prong 7 tab ...

Page 41: ... tank bolt 7 4 breather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 8 fuel line 10 fuel valve bolt 9 fuel valve WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel St...

Page 42: ...r cleaner cover rubber 5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shrouds 8 and shroud B bolts collars 9 Tighten the shroud B bolts to the specified torque 3 7 lbf ft 5 N m 0 5 kgf m 9 Install the shroud A bolts collars 10 8 shrouds 9 shroud B bolts collars 10 shroud A bolts collars 4 fuel tank bolt 6 fuel tank band 5 air cleaner cover rubber ...

Page 43: ...lamp Servicing Your Honda 39 7 Loosen the subframe mounting A bolt 17 and remove the subframe mounting B bolts 18 17 subframe mounting A bolt 18 subframe mounting B bolts 8 Lift the subframe 19 as shown Tighten the subframe mounting A bolt to the specified torque 36 lbf ft 49 N m 5 0 kgf m 1 right side cover bolt 3 collars 2 seat bolt 4 right side cover 2 Open the air cleaner box cover 5 by turnin...

Page 44: ...Installation 1 Loosen the subframe mounting A bolt 2 2 Loosely attach the lower ends of the subframe 1 to the mainframe while connecting the air cleaner connecting tube to the carburetor Then align the subframe with the rear wheel and tighten the subframe mounting B bolts 2 and subframe mounting A bolt 3 to the specified torque B bolts 22 lbf ft 30 N m 3 1 kgf m A bolt 36 lbf ft 49 N m 5 0 kgf m 4...

Page 45: ... or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel...

Page 46: ...tainer 2 Remove the fuel tank page 37 3 Remove the fuel filter 1 from fuel tank by removing the bolts 2 Wash the fuel filter in high flash point cleaning solvent 4 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 3 is in place Install the fuel filter in the fuel tank Refill the fuel tank Attach the fuel valve and fuel line and turn the fuel valve to ON or RES check f...

Page 47: ...lassification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent viscosity weight SAE 10W 40 JASO T 903 standard MA or MB Your motorcycle does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils...

Page 48: ...e engine oil filler cap dipstick If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine ...

Page 49: ...and oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 9 lbf ft 12 N m 1 2 kgf m 15 Install the left engine guard and tighten the left engine guard bolt 16 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69R at oil and filter change 0 70 US qt 0 66R at oil change 17 Install the engine oil filler cap dipstick 18 ...

Page 50: ...ng service label on the container They may affect lubrication and clutch performance API classification 4 stroke engine oil only Viscosity weight JASO T903 standard others suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label SG or higher except oils labeled as energy conserving on the circular API ...

Page 51: ...smission oil filler hole until oil start to flow out of the oil check bolt hole Tighten the oil check bolt with a new sealing washer and transmission oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 ...

Page 52: ... protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection NOTICE Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing ...

Page 53: ...see the Honda Service Manual for troubleshooting of leaks 2 Check the water hoses 1 for cracks deterioration and clamp bands for looseness 3 Check the radiator mount for looseness 4 Make sure the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water l...

Page 54: ...commended coolant mixture page 48 Capacity 1 19 US qt 1 13R 3 Turn the quick fastener 2 counter clockwise 4 Remove the left side cover bolt 3 seat bolt 4 collars 5 and left side cover 6 5 Remove the radiator reserve tank cap 7 and fill the reserve tank to the UPPER level line 8 2 quick fastener 6 left side cover 3 left side cover bolt 7 radiator reserve tank cap 4 seat bolt 8 UPPER level line 5 co...

Page 55: ...oper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear NOTICE Cleaning 1 To open the air cleaner cover 1 turn the quick fastener 2 counterclockwise 3 Pull the air cleaner element 5 out from the air cleaner holder 6 1 air cleaner cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 and air cleaner 4 as shown 5 air cleaner element 8 hole 6 air...

Page 56: ...ner and holder Install the tab 7 of the holder in the hole 8 of the air cleaner tab 9 9 Install the assembly into the air cleaner housing 3 air cleaner retaining bolt 10 access tab 11 mark 52 Servicing Your Honda 10 11 3 10 Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner with the mark 11 of the air cleaner housing by rotatin...

Page 57: ...cycle is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 2 1 ...

Page 58: ...ock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your Honda dealer 5 6 1 Pull the dust cover 2 back 2 Loosen the upper lock nut 3 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the lock nut...

Page 59: ... all steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 Servicing Y...

Page 60: ...d if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained 3 lock nut increase 4 integral cable adjuster decrease 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the ...

Page 61: ...Servicing Your Honda 57 1 rear brake pedal 4 washer 2 pin 5 dust seals 3 pivot bolt 3 Remove the five clutch cover bolts 4 and clutch cover 5 4 clutch cover bolts 5 clutch cover 4 Remove the five clutch spring bolts and clutch springs 6 Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 5 Remove the clutch pressure plate 7 6 clutch spring bolts clutch springs 7 clutch pressure pl...

Page 62: ...udder spring 2 onto the clutch center as shown Coat the clutch discs 3 and plates 4 with clean transmission oil 2 Install the clutch disc A larger I D disc 5 onto the clutch outer Stack the seven clutch plates and seven clutch discs alternately 1 spring seat 4 clutch plates 2 judder spring 5 clutch disc A 3 clutch discs 3 Apply grease to the clutch lifter rod 6 4 Insert the clutch lifter rod into ...

Page 63: ...urn spring 13 rear brake pedal 16 washer 14 pivot bolt 17 Pin 14 Fill the crankcase with transmission oil page 47 Servicing Your Honda 59 17 13 14 15 16 12 6 Install the clutch pressure plate 8 7 Install the five clutch springs and bolts 9 8 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 9 lbf ft 12 N m 1 2 kgf m 8 clutch pressure plate 9 clutch spring bolts spri...

Page 64: ...8 in 2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster in will increase freeplay and turning out will decrease freeplay After adjustment tighten the lock nut 3 lock nut increase 4 adjuster decrease 60 Servicing Your Honda 1 2 4 3 ...

Page 65: ...r damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 03 0 04 in 0 8 0 9 mm 3 sealing gasket 4 spark plug gap 3 4 Servicing Your Honda 61 Standard IMR8C 9H NGK or VUH24D DENSO Optional IMR9C 9H NGK or VUH27D DENSO 7 To obtain...

Page 66: ...ce engine performance 1 seat bolt 3 side cover bolt 2 collars 4 right side cover 2 Loosen the muffler clamp bolt 5 3 Remove the muffler A bolt washer 6 muffler B bolt 7 and muffler 8 5 muffler clamp bolt 7 muffler B bolt 6 muffler A bolt washer 8 muffler 1 4 3 2 2 6 8 7 5 Muffler Removal 1 Remove the seat bolt 1 collar 2 side cover bolt 3 collar 2 and right side cover 4 62 Servicing Your Honda ...

Page 67: ...lt 6 and muffler A bolt washer 7 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 6 Tighten the muffler clamp bolt 8 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 muffler B bolt 8 muffler clamp bolt 7 muffler A bolt washer 9 right side cover 11 side cover bolt 10 collars 12 seat bolt 7 Install the right side cover 9 collar 10 and side cover bolt 11 8 Install the collar 10 seat bolt 12 and...

Page 68: ...hten the nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 63 Exhaust Pipe Removal 1 Remove the muffler page 62 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 1 2 3 1 2 3 ...

Page 69: ...ur engine from reaching the environment 1 Allow the engine and muffler 1 to cool 2 Remove the four bolts 2 spark arrester 3 and gasket 4 from the muffler 1 muffler 3 spark arrester 2 bolts 4 gasket 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of brakes and holes Replace if necessary Che...

Page 70: ...er bolts 3 and cylinder head cover 4 3 cylinder head cover bolts 5 packing 4 cylinder head cover 1 crankshaft hole cap 1 2 3 4 5 1 Refer to Safety Precautions on page 25 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine is cold at the interv...

Page 71: ...t 3 clockwise until aligning the punch mark 4 on the primary drive gear with the index mark 5 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of t...

Page 72: ...2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool Tensioner stopper 070MG 0010100 3 Turn the tensioner shaft clockwise with the stopper tool 3 until it stops in order to retract the tensioner fully Then insert the stopper tool fully to hold the stopper in the fully retracted position 3 stopper tool 1 2 3 3 68 Servicing Your Honda ...

Page 73: ...nto the crankcase Be careful not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6 Remove the valve lifters 7 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left Do not let the valve lifters and shims fall into the crankcase NOTICE 7 valve lifters 7 Remove the ...

Page 74: ... 025 mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposit...

Page 75: ...ylinder head 8 timing marks 10 cam chain 5 Apply grease to the set rings and install it onto the camshaft holders 11 Install the camshaft holder bolts 12 and tighten it to the specified to torque 12 lbf ft 16 N m 1 6 kgf m Tighten the camshaft holder bolts in a criss cross pattern in 2 or 3 steps 11 camshaft holders 12 camshaft holder bolts 2 2 1 4 5 6 12 12 11 Servicing Your Honda 71 3 valve lift...

Page 76: ... Remove the camshaft holders to place the shim correctly and reinstall the camshaft holders VALVE CLEARANCES IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 13 feeler gauge 7 Remove the stopper tool 14 from the cam chain tensioner lifter 14 stopper tool 8 Install a new sealing washer 15 and cam chain tensioner lifter cover bolt 16 15 sealing washer 16 cam chain tensioner lifter caver...

Page 77: ... it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 5 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover bolts 4 Connect the direct ignition coil 7 and breather tube 8 7 direct ...

Page 78: ...ly 9 Remove the air supply pipe bolt 3 PAIR control valve bolts nuts 4 and PAIR control valve 5 california only 1 air suction hose 4 PAIR control valve bolts nuts 2 vacuum hose 5 PAIR control valve 3 air supply pipe bolt 10 Disconnect the direct ignition coil 5 11 Remove any dirt around the spark plug base 5 direct ignitioncoil 12 Remove the cylinder head cover page 66 13 Remove the spark plug 6 6...

Page 79: ... nuts washers 13 and cylinder head 14 Loosen the nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase NOTICE 13 cylinder head nuts washers 14 cylinder head 20 Remove the dowel pins 15 cylinder head gasket 16 and cam chain guide 17 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 15 dowel pins 17 ca...

Page 80: ...op towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hours of running 4 Spread each piston...

Page 81: ...tall the side rails Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring top ring mark side rail oil ring side rail sp...

Page 82: ...stall the piston pin and new piston pin clips 5 Use new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entire t...

Page 83: ...r walls NOTICE 3 cam chain 5 piston rings 4 cylinder 6 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankcase guide hole 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 Do not let the dowel pins fall into the crankca...

Page 84: ...ss pattern in 2 or 3 steps NOTICE NOTICE 4 Install the cylinder bolt 5 and cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 3 cylinder head 4 cylinder head nuts washers 5 cylinder bolt 6 cylinder head bolts 7 engine hanger plate 8 engine hanger nuts bolts of the frame side 9 engine hanger nut bolts of the engine side 4 3 6 5 7 9 8 80 Servicing Your Honda 5 I...

Page 85: ...ol valve bolts nuts 14 and air supply pipe bolt 15 california only 11 Tighten the PAIR control valve nuts and air supply pipe bolt 12 Connect the vacuum 16 and air suction 17 hoses california only 13 Install the exhaust pipe page 64 14 Install the carburetor page 131 15 Install the subframe and muffler page 40 16 Install the fuel tank and the seat page 36 38 17 Fill the cooling system with the rec...

Page 86: ...ean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension adjustment information page 104 for make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment...

Page 87: ... 119 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 119 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression an...

Page 88: ...eal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 1 outer tube 6 guide bushing 5 dust seal 7 slider 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 9 of the fork damper 1 outer tube 9 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork o...

Page 89: ...sion Minimum oil capacity 10 4 US oz 308 cm3 2 scribe marks aftermarket parts No mark factory products 3 scribe marks Optional Stiffer 0 44 kgf mm Fork Spring Standard oil capacity 11 6 US oz 343 cm3 Maximum oil capacity 13 6 US oz 402 cm3 Slightly stiffer as it nears full compression Slightly stiffer as it nears full compression Minimum oil capacity 10 3 US oz 306 cm3 1 scribe mark Be sure the oi...

Page 90: ...ster 1 Loosen the lock nut 1 2 To position the front brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the front brake lever closer to the handgrip turn the adjuster counterclockwise 3 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on ...

Page 91: ... the brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 89 Worn brake pads should be repla...

Page 92: ... lbf ft 1 0 N m 0 1 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 5 bolts 8 diaphragm 6 reservoir cap 9 upper level mark 7 set plate 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 Check the diaphragm installatio...

Page 93: ... 2 front brake caliper Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 4 brake pads 6 brake disc 5 rear brake caliper Other Inspections Check that the front brake lever and rear brake pedal assemblies are positioned properly and the securing bolts are tight ...

Page 94: ...ve the wheels to perform the recommended service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rims 2 spokes 3 rim lock 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spoke 2 7 lbf ft 3 68 N m 0 38 kgf m Rim Lock 9 4 lbf ft 13 N m...

Page 95: ...all a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your motorcycle has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particula...

Page 96: ...o the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Front Rear Type 80 100 21 51M DUNLOP 100 100 18 59M DUNLOP bias ply tube type D742F D756 WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the...

Page 97: ...utions on page 25 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease 1 ...

Page 98: ...t the transmission into neutral 2 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced 1 drive chain plate inner If the chain is found to be slack in one segment of its length and taut in another this indicates that some of the links are either worn kinked or binding Kinking and binding can frequently be elimin...

Page 99: ...a solvent may also damage the O rings 2 Replace the drive chain if it has damaged rollers loose fitting links damaged O rings or other wise appears unserviceable Replacement Chain DID520MXV 3 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly worn drive chain Both chain and sproc...

Page 100: ... surfaces of the link plates and rollers 1 chain slider 2 Check the chain guide slider 2 for wear Replace the chian guide slider if it is worn to the bottom of the wear limit groove 3 2 chain guide slider 3 wear limit groove Drive Chain Rollers 1 Measure the diameter of the drive chain rollers 1 Replace them if below the service limit SERVICE LIMIT UPPER ROLLER 1 1 in 29 mm LOWER ROLLER 1 2 in 31 ...

Page 101: ...Tighten the front bolts first 1 handlebar 2 handlebar upper holders Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant Be certain that the throttle cables have no kinks or other damage 2 1 2 Stand in front of your CRF grab the fork at the axle look at the steer...

Page 102: ...k bolt Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket Torque lbf ft N m kgf m 7 15 7 11 7 7 7 9 7 23 10 21 10 15 10 10 10 12 10 31 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 2 1 0 3 2 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cove boltsr 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 1 3 3 5 4 6 2 9 8 7 10 RIGHT SIDE...

Page 103: ...ttery cables negative cable first NOTICE You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause ...

Page 104: ...sed or lowered Turn the adjusting screw 1 clockwise to move the headlight up or turn the adjusting screw counterclockwise to move the headlight down to proper adjustment Taillight The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibilit...

Page 105: ... dust seals steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your motorcycle You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hon...

Page 106: ...is manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a m...

Page 107: ...to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 104 Rear Suspension Adjustments 118 Su...

Page 108: ...y using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pressure ...

Page 109: ...rings in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn...

Page 110: ...lts 7 fork damper 7 Remove the disc cover 8 by removing the two bolts 9 8 9 3 Disconnect the head light connector 3 8 Remove the tripmeter cable 10 and front axle nut 11 and loosen the axle pinch bolts 12 on both fork legs 9 Pull the front axle shaft 13 out of the wheel hub and remove the front wheel 10 trip meter cable 12 axle pinch bolts 11 front axle nut 13 front axle shaft 10 Remove the fork p...

Page 111: ...ing the lock nut wrench 25 Gently slide the outer tube down onto the lower end of the slider 26 21 22 24 23 25 25 23 26 23 24 23 27 14 fork protector bolts 17 fork protectors 15 tripmeter cable clamp bolts 18 brake caliper bolts 16 brake hose clamp bolts 19 brake caliper 11 Loosen the fork leg lower pinch bolts 20 then pull the fork legs down and out 15 17 14 18 18 19 16 20 Do not support the brak...

Page 112: ...ile applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole NOTICE 28 axle holder 32 push rod 31 lock nut 26 Remove the fork damper assembly 33 from the fork assembly 34 Remove the fork from the vise Remove the fork spring 35 from the fork 33 fork damper assembly 35 fork spring 34 fork assembly 28 30 31 29 28 32 31 33 35 34 17 Temporarily install the fork ...

Page 113: ...lean the fork cap and fork damper threads 2 fork damper 7 Pump the fork damper piston rod 6 slowly several times to bleed the air from the fork damper 2 2 fork damper 6 piston rod 1 3 2 4 2 5 2 2 2 6 6 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 6 US oz 195 cc 6 9 Imp oz...

Page 114: ...ht position and pump the fork piston rod 6 to 3 9 in 100 mm slowly several times 2 3 1 10 Tighten the fork cap 1 while holding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 2 fork damper 9 Apply fork oil to the bushing 7 and new O ring 8 on the fork cap 1 assembly Extend the fork damper piston rod to maximum holding it install the f...

Page 115: ...g chamber through the oil hole and cause 175 cm3 of fork fluid to be left in the chamber 13 Blow the extra oil off to the fork damper spring chamber 10 by pumping the fork damper piston rod to full stroke 15 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure r...

Page 116: ...nverted for about 20 minutes at 20 C 1 outer tube slider 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Using compressed air blow all oil off the fork spring 3 Install the fork spring Install the fork damper 4 to the outer tube slider 1 1 outer tube slider 4 fork damper ...

Page 117: ...n the center bolt fully by hand NOTICE 2 lock nut 7 O ring 5 stopper tool 8 center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten t...

Page 118: ...US oz 303 cm3 Optional Softer 0 40 kgf mm Fork Spring Standard oil capacity 11 7 US oz 345 cm3 Maximum oil capacity 13 6 US oz 404 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 4 US oz 308 cm3 No mark factory products 3 scribe marks 2 scribe marks aftermarket parts or Optional Stiffer 0 44 kgf mm Fork Spring Standard oil capa...

Page 119: ...ion the outer tubes so that the pressure release screws are in front of the rebound damping adjusters Align 15 the top surface of the upper fork clamp 16 with the outer tube 1 upper surface as shown 19 Tighten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 20 Tighten the fork upper pinch bolts 17 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m Over tightening t...

Page 120: ...r box 27 grooves 25 Clean the clamping surface of the axle and axle holders Install the front wheel 28 between the fork legs while inserting the disc between the pads and align 29 the tab of the tripmeter gear box as shown Cjeck that the tripmeter gear box O ring 30 is in good condition replace it if necessary Apply a thin layer of grease to the axle 31 and insert the axle from the right side 21 1...

Page 121: ...r pad 30 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 31 While keeping the forks parallel alternately tighten the right axle pinch bolts 41 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 41 axle pinch bolts 42 tripmeter cable 33 Install the disc cover 43 and tighten the bolts 44 to the specified torque 10 Ibf ft 13 N m 1 ...

Page 122: ...Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and rem...

Page 123: ...peed damping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 3 4 2 1 4 turns and the punch marks are aligned Low Speed Damping The low speed da...

Page 124: ...sion tuning the proper rear spring pre load adjustment for your specific needs Your motorcycle should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of...

Page 125: ...imension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your motorcycle With the spring pre load set to obtain the proper race sag the rear suspension should sag 10 to 25 mm 0 4 to 1 0 in If the rear of your motorcycle sags more than 25 mm 1 0 in from its own weight the spring is too stiff for your weight It is not compressed enough ...

Page 126: ...r aftermarket springs front and rear may help especially if you are heavier than the average rider Your motorcycle may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways com...

Page 127: ...n large bumps especially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because ...

Page 128: ... makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is st...

Page 129: ...bumps Entire travel too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment ...

Page 130: ...er when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must be...

Page 131: ...rcuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 air passage 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters t...

Page 132: ...rear suspension upper mounting bolt 4 2 band 3 upper mounting nut 4 upper mounting bolt 6 Lift the sub frame to the upright position page 39 7 Loosen the intake band screw 5 5 intake band screw 8 Disconnect the throttle position sensor connector 6 Remove the carburetor 6 throttle position sensor connector 9 Remove the hot start cable holder 7 7 hot start cable holder 2 3 4 5 6 7 WARNING Gasoline i...

Page 133: ... arm set screw 7 When installing the link arm set screw apply a locking agent to the link arm set screw threads 4 Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 7 link arm set screw 9 throttle valve roller 8 throttle valve 10 floating valve 2 1 3 6 5 4 7 8 9 10 8 10 Remove the throttle drum cover bolt 8 and throttle drum cover 9 8 throttle drum cover bolt 9 throttle drum...

Page 134: ...ling the D ring into the accelerator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 13 accelerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws ...

Page 135: ...o assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures Tighten the following parts to the specified torque float bowl screws 1 5 lbf ft 2 1 N m 0 2 kgf m accelerator pump cover screws 1 5 lbf ft 2 1 N m 0 2 kgf m top cover bolts 1 5 lbf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 lbf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 lbf ft 2 1 N m 0...

Page 136: ...tart it and warm it up three minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift into neutral Start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the throttle stop screw 2 Idle speed 1 700 100 rpm 1 throttle stop screw 1 4 air vent hoses 5 overflow hose 5 4 4 5 4 ...

Page 137: ... 120 in the 90 100 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the fork tube 1 with the top of the upper fork clamp 2 STANDARD POSITON Wheelbase Adjusting your motorcycle s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the ...

Page 138: ...ese conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth to keep the engin...

Page 139: ...emember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unus...

Page 140: ...er is depressed when sitting or standing comfortably on your motorcycle Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved forward either 3 mm using optional handlebar lower holders or 6...

Page 141: ...37 Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 138 Storing Your Motorcycle 139 You the Environment 141 Troubleshooting 142 ...

Page 142: ...ailer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary an...

Page 143: ... forgotten and it will be easier to get your motorcycle running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter page 44 3 Change the transmissi...

Page 144: ...tlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the battery page 99 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 27 US qt 1 20R at disassembly 1 19 US qt 1 13R at draining Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from t...

Page 145: ...leaning solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil a...

Page 146: ...lty direct ignition coil Broken or shorted direct ignition coil wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel line at carburetor and check for clogging P 41 UNRESTRICTED FUEL FLOW FUEL FLOW RESTRICTED DIRTY 2 Remove air cleaner P 51 AIR FILTER NOT DIRTY La...

Page 147: ...Taking Care of the Unexpected Taking Care of the Unexpected 143 This section gives practical advice to help you problems If a Fuse Blows 144 If Your Battery is Low or Dead 145 ...

Page 148: ...ollars 4 right side cover 3 Disconnect the wire connector 5 of the starter magnetic switch 6 4 Pull main fuse 7 out If it is blown 8 install the spare main fuse 9 5 wire connector 6 starter magnetic switch 7 main fuse 8 blown fuse 9 spare main fuse 5 Reconnect the wire connector If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a...

Page 149: ... battery The greater amperage of an automobile battery when the car engine is running can damage your motorcycle s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer Taking Care of the Unexpected 145 ...

Page 150: ...146 Taking Care of Unexpected ...

Page 151: ...cities and other technical data Vehicle Identification 148 Specifications 149 Torque Specifications 151 High Altitude Carburetor Adjustment 154 Emission Control Systems 155 Oxygenated Fuels 156 Competition Logbook 157 Optional Parts List 159 Spare Parts Equipment 160 Wiring Diagram 161 ...

Page 152: ...rts You may record these numbers in the Quick Reference section at the rear of the manual The Vin vehicle identification number 1 appears on the Safety Certification Label attached to the left side of the frame LEFT SIDE 1 vin The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number...

Page 153: ...ng and oil filter change After disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR02A 130 NCVT Needle clip position standard Slow jet standard Pilot screw opening Float level Idle speed Liquid cooled 4 stroke 3rd groove 40 2 1 4 turns out 1 700 100 rpm Type Metric 660 cm3 690 cm3 850 cm3 670 cm3 75...

Page 154: ...n Starting system Spark plug Standard For extended high speed riding ICM Startermotor Kickstarter Battery 12V 4 Ah Light Head light 12V 35 W Fuse Main fuse 15 A Left foot operated return system 1 N 2 3 4 5 IMR8C 9H VUH24D IMR9C 9H VUH27D 15 22 cu in 0 70 US qt 0 73 US qt 0 90 US qt 0 71 US qt 0 79 US qt 249 4 cm3 After disassembly Cooling system capacity After draining 1 19 US qt 1 13R 1 27 US qt ...

Page 155: ...GINE Cylinder head cover Clutch cover Water pump cover Torque Remarks lbf ft N m kgf m 7 7 7 10 10 10 1 0 1 0 1 0 5 6 7 8 9 10 Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolt Exhaust pipe joint nut Drive Sprocket 4 Transmission oil check bolt 11 9 7 7 15 23 15 12 10 10 21 31 1 5 1 2 1 0 1 0 2 1 3 2 7 10 1 0 9 3 3 4 5 2 1 8 7 10 6 ...

Page 156: ...racket bolts 40 54 5 5 10 Engine mounting bolts 47 64 6 5 8 Rear axle nut 94 127 13 0 7 Front axle pinch bolts 14 20 2 0 6 Front axle nut 65 88 9 0 NOTE 4 NOTE 2 4 NOTE 2 4 14 Shock absorber upper lower 33 33 44 44 4 5 4 5 NOTE 4 NOTE 4 9 Chain adjuster lock nuts 20 27 2 8 NOTE 5 NOTE 4 5 Handlebar holder nuts 33 44 4 5 4 Handlebar upper holder bolts 16 22 2 2 3 Fork bridge lower pinch bolts 14 20...

Page 157: ... NOTE 7 NOTE 4 NOTE 4 NOTE 7 35 36 37 Muffler clamp bolt Driven sprocket nuts Seat mounting bolts 15 24 19 21 32 26 2 1 3 3 2 7 NOTE 4 41 Side stand mounting bolts upper lower 40 29 54 39 5 5 4 0 40 Fork air pressure release screw 0 9 1 2 0 12 39 Rear brake reservoir cap bolts 0 7 1 0 0 1 38 Front brake reservoir cap screws 0 7 1 0 0 1 34 Muffler mounting bolts front rear 19 19 26 26 2 7 2 7 21 Fr...

Page 158: ...to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine overheating and damage 154 Technical Information High Altitude Carbur...

Page 159: ...nt which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by yo...

Page 160: ...ol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performa...

Page 161: ...on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircra...

Page 162: ...chnical Information Date Running Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Competition Logbook ...

Page 163: ... 53 Teeth Aluminum 116 Optional 54 Teeth Aluminum 116 Optional no offset 52 Teeth Aluminum 116 Handlebar lower holder Standard 3 mm offset TOOLS Remarks For checking tire air pressure Pin spanner A Workstand To adjust spring preload two spanners required For maintenance Air gauge ENGINE Remarks Cooling system assembly Orange Red and Black 280 lbf in 5 00 kgf mm 291 2 lbf in 5 20 kgf mm White Blue ...

Page 164: ...rench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your motorcycle purchased from your Honda dealer Clutch Center Holder 07...

Page 165: ...Technical Information 161 Wiring Diagram ...

Page 166: ...162 Technical Information ...

Page 167: ...Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 164 Contacting Honda 165 Your Honda Dealer 166 The Honda Rider s Club USA only 167 ...

Page 168: ...l 48 00 31KSC620 2006 CRF250X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation S H I P T O NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation Customer Name Attention Street A...

Page 169: ...es at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following infor...

Page 170: ...ondaline accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information US...

Page 171: ...long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Speialty Vehicle Institute of America for ATV owners One f...

Page 172: ... Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Filters Fuel System 41 Engine Oil 43 Transmission Oil 46 Coolant 48 Air Cleaner 51 Crankcase Breather 53 Engine Throttle 54 Clutch System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74 Chassis Suspension 82 Front Suspension Insp...

Page 173: ...nt 154 Emission Control Systems 155 Oxygenated Fuels 156 Competition Logbook 157 Optional Parts List 159 Spare Parts Equipment 160 Wiring Diagram 161 CONSUMER INFORMATION 163 Authorized Manuals 164 Contacting Honda 165 Your Honda Dealer 166 The Honda Rider s Club USA only 167 TABLE OF CONTENTS 168 INDEX 170 QUICK REFERENCE 174 Table of Contents 169 ...

Page 174: ...ment 154 removal 128 care appearance 101 chain drive 94 chassis adjustment for track conditions 135 cleaner air 51 cleaning appearance care 101 clutch system adjustment 56 consumer information 163 competition logbook 157 contacting Honda 165 controls operating 8 coolant 48 cylinder removal 76 damping adjustments front 104 rear 118 dealer your Honda 166 diagram wiring 161 drive chain 94 engine floo...

Page 175: ...s 8 optional parts list 159 sprockets 159 oxygenated fuels 156 pads brake 89 parts optional 159 personal fit adjustments 136 pinging engine 41 plug spark 61 pre load rear suspension 118 pre ride inspection 11 protective apparel 2 rear suspension maintenance 83 Rider s Club Honda 167 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words ...

Page 176: ... oil 46 tuning tips 126 throttle freeplay 54 inspection 55 tires air pressure 91 inspection 91 selection 92 tools 160 torque specifications 151 153 transporting 138 tripmeter 14 troubleshooting 142 tubes replacing 91 valve fuel 15 valve clearance 66 vehicle identification 148 washing your motorcycle 101 wheels 90 wiring diagram 161 W V T ...

Page 177: ...Memo 173 ...

Page 178: ...174 Memo ...

Page 179: ...Memo 175 ...

Page 180: ...ts service frequencies for about every 2 5 hours about every 7 5 hours about every 22 5 hours and about every 30 0 hours Check the items listed on the Pre Ride inspection checklist each time before you ride page 11 unleaded gasoline pump octane number of 91 or higher tank 2 19 US gal 8 3R reserve 0 40 US gal 1 5R Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdem additives 4 stroke oil o...